Packaging container comprising an outer cardboard structure and an insert made of plastic film

ABSTRACT

The invention relates to a packaging tray comprising an outer cardboard structure, inside which a plastic insert is provided. The invention further relates to a method for producing such a packaging tray and a packaging machine on which the packaging tray of said type and packaging to be produced thereby can be produced.

The present invention relates to a packaging tray comprising an outer cardboard structure, in which an insert made of plastic is provided. The present invention further relates to a method for producing a packaging tray of this type and to a packaging machine, on which the packaging tray of this type and packagings to be produced thereby can be produced.

The packaging tray of this type is known for example from FR2933329, FR2826938, FR2883223, EP2097177A2, FR2610595, and DE19602829. The packaging trays described in those documents are comparatively difficult to produce, however, and have disadvantages, in particular in terms of their handling, in particular when the product is heated in the packaging or after such a heating process.

The object of the present invention was therefore to provide a packaging tray that does not have the disadvantages of the prior art.

The object is solved by a packaging tray comprising an outer cardboard structure, in which an insert made of plastic is provided, wherein a gas cushion or a gas space is provided between the cardboard structure and the insert, at least over portions.

The disclosure concerning the packaging tray applies equally to the other subjects of the invention in this patent application and vice versa.

The present invention relates to a packaging tray comprising an outer cardboard structure. The cardboard from which the structure is fabricated may be a single-layer or multi-layer cardboard material. The cardboard material preferably comprises cellulose, ground-wood pulp and/or wastepaper. The cardboard may have inclusions of air. On its inner face, the cardboard material may have a coating that makes it resistant to the effect of lipids and/or water vapor. This layer is particularly preferably sealable. This cardboard structure is preferably produced by folding and possibly by subsequent integral bonding, for example gluing, of a cardboard sheet or of a cardboard blank. After folding, the cardboard structure may also be fixed in its folded structure by a positive and/or non-positive fit. An insert made of a plastic film is introduced into this cardboard structure. The plastic film can be any thermoformable plastic film known in the field of food engineering to a person skilled in the art, for example the plastic film is a soft film or a hard film made of PP, PA/PE, PVC, A-PET or an expedient mixture of these components or integrally bonded layers of these components.

In accordance with the indention, a gas cushion is then provided between the cardboard structure and the insert, in particular over portions. The gas cushion is preferably an air cushion. For example, this gas cushion is produced since the insert is shaped differently from the cardboard structure so that, when the insert and cardboard structure are assembled, there is a spacing between the insert and the cardboard structure, in which gas, in particular air, is located. This spacing is preferably greater than the usual tolerance, and it is therefore ensured that the insert and the cardboard do not contact one another, at least over portions, even if the insert is filled. The spacing is preferably more than 0.5 mm, more preferably more than 1 mm, and more preferably more than 2.5 mm. The gas cushion may also however be provided in the form of a structure, for example in the form of a gas cushion film or a corrugated board or the like. This gas cushion may increase when the packaging is heated for example. The insert preferably contacts the cardboard structure over the smallest possible area in the region of the gas cushion. In particular, the area of contact between the insert and the cardboard structure in the region of the gas cushion is extremely low, however.

The gas cushion may preferably be provided, at least over portions, as a storage space, for example for cutlery and/or condiments, with which a foodstuff that is filled into the insert can be eaten and seasoned.

In accordance with a preferred or a further embodiment according to the invention of the packaging tray, the contour of the insert does not follow the contour of the cardboard, at least over portions. It is thus ensured that a spacing forms between the insert and the cardboard structure, in which a gas cushion is then automatically provided. This spacing is preferably greater than the usual tolerance, thus ensuring that the insert and the cardboard do not contact one another, at least over portions, even if the insert is filled. The spacing is preferably more than 0.5 mm, more preferably more than 1 mm, and more preferably more than 2.5 mm.

The comments made with regard to this embodiment of the packaging tray likewise apply to the other packaging trays according to the invention and vice versa.

In accordance with a preferred embodiment, the insert has a side wall, which extends along the entire periphery of the insert. This side wall can have any form with which a person skilled in the art is familiar. For example, it can be quadrangular, oval or round. This side wall preferably has a step, and therefore the periphery of the insert tapers, and preferably tapers from the edge of the packaging toward the base. This step may have any form with which a person skilled in the art is familiar. This step is preferably molded into the insert when forming, preferably thermoforming, a film web from which said insert is produced. The cardboard structure does not follow this tapering, or does not follow it to the same extent, and therefore a spacing between the insert and the cardboard structure is produced, in which gas is then located, which acts as a gas cushion and/or can be used as a storage space.

The gas cushion is preferably located between the side wail of the insert and the side wall of the cardboard structure, at least over portions. The gas cushion is preferably located in the lower region of the packaging tray, in particular in the lower region of the side wall and/or, at least in part, in the region of the base. The gas cushion is most preferably located in the region that comes into contact with the fingers and/or palm of the hand when the packaging tray is grasped. The gas cushion preferably still exists, at least over portions, once the insert has been filled with the packaging content.

The cardboard structure and the insert are generally bonded integrally to one another. This integral bond can be produced by gluing or sealing, wherein sealing is preferred. The cardboard structure and the insert are preferably bonded integrally to one another in the upper edge region of the side wall. This integral bond is preferably provided merely locally and not over the entire periphery. The insert is thus connected to the cardboard structure in a stable and durable manner, but the connection can be detached again relatively easily to dispose of the packaging tray. The packaging tray according to the invention further preferably has a connection point between the cardboard structure and the insert in the base region of the packaging tray. The packaging tray according to the invention further preferably has an expedient storage space between the cardboard structure and the insert in the base region of the packaging tray, for example for receiving aids such as a spoon or fork or preparation instructions for (preferably) foodstuffs as the packaging content, or assembly instructions and/or tools for packaging content such as toys. This storage space is preferably part of the gas cushion. The cardboard structure preferably has an access means for access to this storage space. For example, an access means of this type is at least one flap in the cardboard structure, said flap being easily opened for example by partial perforation or a self-adhesive film. The storage space may preferably receive an insert, either alternatively or in addition, by means of which the insert can be provided in the cardboard structure in a height-adjustable manner, for example so as to also compensate for dimensional tolerances caused by the packaging content or so as to be able to use one cardboard structure for a plurality of inserts. The gas cushion must be maintained however, at least in part.

In accordance with a preferred embodiment, the wall thickness of the insert in the base region thereof is smaller than in the region of the side walls. The insert preferably has a sealing edge. This sealing edge protrudes preferably perpendicular, in particular horizontally, from the side edge of the packaging tray and/or, with an edgeless embodiment, is integrated into the region of the side wall. The sealing edge also preferably lies completely within the cardboard structure of the packaging tray.

Once the packaging tray has been filled with the packaging content, the packaging is closed by a cover.

The cover is preferably sealed at the sealing edge of the insert.

In accordance with a further embodiment, an additional cardboard cover is provided that is used, for example, to protect the insert closed by film. The additional cover is connected for example as a separate cover to the insert closed by film and/or to the cardboard structure, and for example is fitted and/or sealed on. The additional cover can also be provided in a foldable manner on the cardboard structure however, for example by perforation. The additional cover is preferably attached in the sealing station or in a separate station, for example after the sealing station.

The present invention further relates to a method for producing a packaging tray comprising an outer cardboard structure, in which an insert made of plastic is provided, wherein the insert is completely thermoformed before it is placed into the cardboard structure.

The disclosure concerning the method applies equally to the other subjects of the invention in this patent application and vise versa.

In accordance with the method according to the invention, the packaging tray obtains its final form, at least substantially, before the cardboard structure is slid over the insert, in particular before the cardboard structure and the insert are interconnected.

The method according to the invention has the advantage that the insert may have a different cross-sectional form compared to the cardboard structure. For example, it is thus possible to provide a spacing between the cardboard structure and the insert and to therefore provide a gas cushion, in particular an air cushion, a storage space or the like.

The cardboard structure is preferably fitted onto the insert from beneath, once said insert has been brought beforehand into its desired form, for example by thermoforming.

The cardboard structure is then preferably bonded integrally to the insert. This integral bond is preferably achieved by scaling, by pressing the insert and the cardboard structure against one another, in particular locally, and/or by introducing energy, for example in the form of heat, ultrasound and/or radiation, in the region of the desired connection points.

The present invention further relates to a packaging machine comprising a thermoforming station, a filling station and a sealing station, wherein a connecting station is additionally provided between the sealing station and the thermoforming station and connects a thermoformed insert to a cardboard structure.

The disclosure concerning the packaging machine applies equally to the other subjects of the invention in this patent application and vice versa.

The insert and the cardboard structure preferably have their final form, at least substantially, before they are interconnected.

The insert is preferably transported in a first direction along the packaging machine before it is connected to the cardboard structure. The cardboard structure is transported along second directions, preferably two second directions, which each preferably run perpendicular to the first transport direction and are roost preferably arranged perpendicular to one another. The cardboard structure is preferably transported by means of a handling system and/or a robot.

When connecting the insert to the cardboard, the insert may be transported along the packaging machine, that it is to say it may move or may be stationary.

The present invention further or preferably relates to a packaging machine comprising a thermoforming station, a filling station and a sealing station, wherein a connecting station is integrated into the sealing station or thermoforming station and connects an insert to be thermoformed or a thermoformed insert to a cardboard structure.

The disclosure concerning the packaging machine applies equally to the other subjects of the invention in this patent application and vice versa.

If the connecting station is integrated into the forming station, the insert is merely formed from one side, for example with assistance by a male mold, whilst it is introduced into the cardboard structure and connected. If the connecting station is integrated into the sealing station, the insert and the cardboard structure have their final form, preferably at least substantially, before they are interconnected.

The invention Will be explained hereinafter on the basis of FIGS. 1 to 3. These explanations are merely exemplary and do not limit the general inventive concept. The explanations apply equally to all subjects of the present invention.

FIG. 1 shows the packaging according to the invention.

FIG. 2 shows the connection of the insert to the cardboard.

FIG. 3 shows the packaging machine according to the invention.

The packaging tray 1 according to the invention is illustrated in FIG. 1. It consists of as outer cardboard structure 2 and an insert 3. The cardboard structure has walls 2.1 and a base 2.2. The cardboard structure is preferably produced from a planar cardboard by folding the side walls 2.1 upwards and gluing them together. The side walls 2.1 preferably do not stand perpendicular on the base, but are arranged such that the cross section of the cardboard structure tapers from top to bottom, thus facilitating the connection/release of the cardboard structure to/from the insert. In the present case, the packaging tray, that is to say in particular including the cardboard structure, is quadrangular, in this case square. An insert 3 is provided in the cardboard structure and has a base 3.1, a side wall 3.2 and a sealing edge 3.4. The packaging tray can be closed with an integral bond at the sealing edge 3.4 by a cover (not illustrated) so as to form a finished packaging, once a packaging content has been filled into the insert 3 of the packaging tray. The insert 3 is connected locally to the side wall 2.1 of the cardboard structure 2 at least at one connection point, and in this case at four connection points 5. This connection is made preferably in the upper edge region 3.5 of the side wall, but more preferably outside the region in which the gas cushion is located. In the present case, four connection points 5 are provided in the upper edge region 3.5 and are preferably arranged equidistantly. The connection 5 between the insert and the cardboard is preferably made by sealing. If required, a further connection point 5 can be provided in the base region 2.2, 3.1, at which the insert is then likewise connected to the cardboard structure by sealing. In accordance with the invention, a gas cushion 4 is then provided between the insert 3 and the cardboard structure 2, at least over portions, that is to say locally. The gas cushion 4 extends in the edge region in the present case, in particular peripherally, between the side wall 2.1 of the cardboard structure and the side wall 3.2 of the insert 3, in particular in the lower region of the packaging tray. If required, a gas cushion is also provided in the base region 2.2, 3.1, at least locally. The gas cushion generally has the same pressure as the ambient pressure. So as to produce the local spacing between the insert 3 and the cardboard structure 2, the side wall 3.2 of the insert 3 in this case has a step 3.3 so that the cross section of the insert tapers from the upper end downwards. In the present case, the step is substantially right-angled. A person skilled in the art understands, however, that the step may have any other form, provided it merely results in the formation of a spacing between the side wall of the cardboard structure and the side wall of the insert. The step illustrated in this case, however, has the advantage that it lends the insert 3 additional dimensional stability, which is advantageous in particular when assembling the cardboard structure 2 and the insert 3. A person skilled in the art understands, for example, that the cardboard structure may also have a step so as to produce a spacing between the side walls 2.1., 3.2. The gas cushion 4 between the side walls 2.1, 3.2 and possibly between the base portions 2.2, 3.1 has the advantage that the temperature of the cardboard structure when the packaging content within the packaging tray is heated, for example by microwaves, is at least temporarily lower than the temperature of the packaging content.

FIG. 2 shows the assembly of the insert 3 and the cardboard structure 2. It can be clearly seen that, before the cardboard structure 2 and the insert 3 are interconnected, said insert already has its thermoformed form. Only once the insert 3 has been brought into its substantially final form is the cardboard structure slid onto the insert, preferably from beneath, as illustrated by the arrow, and/or is the insert 3 moved relative to the cardboard structure, said cardboard structure and insert then being interconnected at the connection points 5, wherein the connection point 5 in the base region is merely provided optionally. The cardboard structure also has its final form, at least substantially, before the connection process.

FIG. 3 shows the packaging machine 6 according to the invention. This packaging machine is what is known as a “form-fill-seal machine”, in which a film web is unrolled from a film roll 7 and is transported along the packaging machine, as symbolized by the arrow 13, and in, particular is transported intermittently. With each intermittent pulse, a format consisting in this case of nine units is transported simultaneously and is processed simultaneously. In a first step, nine inserts 3 are molded into the film web with each intermit tent pulse, in particular by thermoforming. This format consisting of nine inserts then continues to be transported intermittently until it reaches the connecting station 9. Here, the inserts 3 are each connected to a cardboard structure 2. In this method step, the inserts 3 are stationary or the inserts move. To connect the inserts 3 to the cardboard structures 2, the cardboard structures are first positioned beneath the respective insert from a position remote from the packaging machine and are positioned in a plate for example, which has nine recesses in this case. The cardboard structures 2 already have their three-dimensional form. The cardboard structures 3 are then raised simultaneously and slid over the inserts 2 until they have reached their desired end position relative to the insert 3, Each of the inserts 3 is then bonded integrally to a respective cardboard structure 2. This can be achieved tor example by pressing sealing jaws against the insert 3 from the inside and by connecting the insert 3 to the cardboard structure 2. An abutment is generally required for this purpose, preferably on the side of the sealing jaws opposite the packaging tray, and is preferably provided in the plate, most preferably so as to be at least partially resilient, for example rubber-coated. Both the movement of the cardboard structures beneath the inserts 3 and the lifting thereof for connection of the inserts to the cardboard structure are achieved preferably as a result of movements provided perpendicular to the first transport direction 11 of the inserts 3 and/or perpendicular to one another. The inserts and the cardboard structures, which are now interconnected, are then transported intermittently to a filling station 10, in which each packaging tray 1 is filled with a packaging content. The packaging tray thus finished is then closed in the sealing station 11 by a cover, which is preferably sealed at the sealing edge under the effect of pressure and/or temperature. A gas exchange may take place in the packaging tray before the packaging tray is closed and/or during said process. The cover film may be what is known as a “skin film”. The packagings thus finished are then separated in a separating station 12, in which the plastic web from which the inserts 3 have been produced and the cover film web are cut around the inserts.

LIST OF REFERENCE SIGNS

-   1 packaging tray -   2 outer cardboard structure -   2.1 side wall -   2.2 base -   3 insert made of plastic film -   3.1 base -   3.2 side wall -   3.3 step -   3.4 sealing edge -   3.5 upper edge region of the side wall -   4 gas cushion, air -   5 connection point -   6 packaging machine -   7 film roll -   8 thermoforming station -   9 connecting station -   10 filling station -   11 sealing station -   12 separating station -   13 first transport direction -   14 second transport direction 

1. A packaging tray comprising: an outer cardboard structure, in which an insert made of plastic film is provided, wherein a gas cushion is provided between the cardboard structure and the insert, at least over portions, wherein the cardboard structure and the insert are bonded integrally to one another in the upper edge region of the side wall, and wherein the integral bond is only provided locally and not over the entire periphery. 2-18. (canceled)
 19. The packaging tray of claim 1, wherein the contour of the insert does not follow the contour of the cardboard, at least in portions, wherein the insert has a side wall, and in that a step is provided in this side wall.
 20. The packaging tray of claim 1, wherein the wall thickness of the insert in the base region is smaller than in the region of the side wall.
 21. The packaging tray of claims 1, wherein the packaging tray has a storage space, at least in portions, between the cardboard structure and the insert, in particular in the base region of the packaging tray.
 22. The packaging tray of claim 21, wherein a means for opening the cardboard structure is provided in the cardboard structure in the region of the storage space, in the base region, so as to obtain access to the storage space.
 23. The packaging tray claim 22, wherein an aid and/or a meal component is arranged in the storage space.
 24. A method for producing a packaging tray comprising: an outer folded cardboard structure, in which an insert made of plastic film is provided, wherein the insert is completely thermoformed before it is introduced into the folded cardboard structure.
 25. The method as claimed in claim 24, wherein the cardboard structure is fitted onto the insert from beneath.
 26. The method as claimed in claim 24, wherein the cardboard structure is bonded integrally to the insert.
 27. A method for producing a packaging tray comprising: an outer folded cardboard structure, in which an insert made of plastic film is provided, wherein the insert is thermoformed at least in part while the insert is introduced into the folded cardboard structure, wherein the folded cardboard structure is fitted from beneath onto the insert, which is still unformed, and said insert is formed subsequently and/or simultaneously.
 28. The method as claimed in claim 27, the cardboard structure is bonded integrally to the insert.
 29. The method of claim 27, wherein the packaging tray is produced in a packaging machine comprising:
 1. a thermoforming station,
 2. a filling station and
 3. a sealing station,
 4. a connecting station between the sealing station and the thermoforming station and connects a thermoformed insert to a folded cardboard structure.
 30. The method of claim 29, wherein a connecting station is integrated into the thermoforming station and connects a thermoformed insert to a cardboard structure.
 31. The method of claim 29, wherein before the insert is connected to the cardboard structure, the insert is transported in a first direction in the packaging machine, and in that said packaging machine transports the cardboard structure along two second directions, which each run perpendicular to the first transport direction.
 32. The method of claim 29, wherein handling devices and/or robots are provided for the transport of the cardboard.
 33. The method of claim 24, wherein the packaging tray is produced in a packaging machine comprising: a) a thermoforming station; b) a filling station; c) a sealing station; and d) a connecting station between the sealing station and the thermoforming station and connects a thermoformed insert to a folded cardboard structure.
 34. The method of claim 33, wherein a connecting station is integrated into the thermoforming station and connects a thermoformed insert to a cardboard structure.
 35. The method of claim 33, wherein before the insert is connected to the cardboard structure, the insert is transported in a first direction in the packaging machine, and in that said packaging machine transports the cardboard structure along two second directions, which each run perpendicular to the first transport direction.
 36. The method of claim 33, wherein handling devices and/or robots art provided for the transport of the cardboard.
 37. The method of claim 38, wherein the packaging tray comprises: an outer cardboard structure, in which an insert made of plastic film is provided, wherein a gas cushion is provided between the cardboard structure and the insert, at least over portions, wherein the cardboard structure and the insert are bonded integrally to one another in the upper edge region of the side wall, and wherein the integral bond is only provided locally and not over the entire periphery. 